Spatulated fiber



May l?, 1966 Original Filed Aug. l5, 1962 G. SHAW SPA'IULATED FIBER 8 Sheets-Sheet 1 F'lG.3A- FI G A.

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INVENTOR. Gl L BERT Sl-IAVV ATTORNEYS May 17, 1966 Original Filed Aug. l5, 1962 THICK/V555 IN [NCI/[5 sr/frA/fss G. SHAW 3,251,729

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DISTANCE FROM NON-.fwfrP/Na END pmfcno- 0F .swffPJ/M Np INVENTOR.

G I L BE'RT SHAW ATTORNEYS May 17, 1966 G. sHAw 3,251,729

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ATTORN EYS May 17, 1966 G. sHAw 3,251,729

SPATULATED FIBER Original Filed Aug. l5, 1962 8 Sheets-Sheet 4 F l G. I2.

INVENTOR. G I LB E RT SHAW Iglu/5744 il@ v L ATTORNEYS May 17, 1966 G. sHAw I SPATULATED FIBER 8 Sheets-Sheet 5 Original Filed Aug. l5, 1962 F l G- I6.

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INVENTOR. GILBERT SHAW A TORNEYS May 17, G SHAW SPATULATED FIBER 8 Sheets-Sheet 6 Original Filed Aug. l5, 1962 FIG-24 FIG-25 INVENTOR. G L B E R T S H AVV BY @@agvmz ATTOFRN EYS May 17, 1966 G. SHAW 3,251,729 SPATULATED FIBER Original Filed Aug. l5, 1962 8 Sheets-Sheet 7 F I G.. 26

26A 26B 26C 26A 26B 26C TYPES 0F CONF/aURAT/ONS /N DOUBLE-JPATULATED FSRES FIG. 2e y 757: 15 E SECT/0N B-B FICLZVGA f-lclze Q Q SECTON C-C I v 1:16.26

FIG- 26C INVENTOR. G L .BERT SHAW W078i, Mln) )WQ ATTORNEYS May 17, 1966 G. sHAw Original Filed Aug. 15, 1962 @as Mm) v 8 Sheets-Sheet 8 Gl LBEFIT' SHAW ATTORN EYS United States Patent O 3,251,729 SPATULATED FIBER Gilbert Shaw, Middlebury, Vt.

Original application Aug. 15, 1962, Ser. No. 217,000, now Patent N0. 3,184,822, date'd May 25, 1965. Divided and this application May 1, 1963, Ser. No. 283,653

3 Claims. (Cl. 161-179) This application is a division of my co-pending application, Serial No. 217,000, iiled August l5, -l962 now U.S. Patent 3,184,822 granted May 25, 1965.

This invention relates to improved synthetic brush bers. i

During the last twenty-ve years, synthetic bers, mainly in oriented lament form, have found increasing usage as brush bers. Their acceptance has been brought about as a result of decreasing supplies of natural brush lling materials, the greater demand for natural brush lling materials caused by overall world population growth and greater purchasing power, and the rising trend of natural brush ber prices that parallels world prices in general.

Although various efforts have been made to modify the shape and composition of synethetic brush bers to permit closer approximation of the action of natural brush lling materials, synthetic materials have in many instances fallen short of the performance of natural materials. Brush manufacturing methods, highly developed for handling natural materials, have remained essentially unchanged in the face of replacement of natural materials by synthetics Aand have never fully utilized the basic physical properties of synthetic brush lling materials.

The need for improved synthetic brush bers and brush constructions can be illustrated by describing the major desirable properties of natural bers, and by reviewing the efforts that have been made to make synthetic bers more acceptable in the past.

Hog bristles are admirably suited for use in paint brushes and other uses. TheyV possess a diameter reduction in the direction of the working or painting end; The attendant decrease in stiffness in the direction of the workj ing end is highly desirable because of the flexing hand imparted to a brush. At the working end of each hog bristle, the bristle splits into a multiplicity of ner laments which is customarily called the liower or ag. The liag facilitates smooth application of paint or liquids. As the bristles wear down, the flag continues to split olf the main bristle stem so that excellent performance from a painting standpoint continues as the bristle wears. Follicles are present along the length of the bristle stem which add to the paint holding capacity of a hog bristle vbrush because of capillary action.

ered synthetic ber, there is a tendency for the flag to wear and leave a small circular tip that is a poor paint applicator.

Paint brushes having X cross section bers rather than solid circular have been devised. These' have excellent capillarity and continue to ag in service but as yet, they have not been supplied with Ydecreasing stine'ss in the direction of the Working ends. Y

In the instance of brooms which are made using broom corn, the desirable features of broom corn are similar 3,251,729 Patented May 17, 1966 ICC in many respects to those present in hog bristles. The individual corn fibers have a decreasing diameter in the direction of the working or sweeping end. Each ber has a ower or ag at its sweeping end consisting of about l to 8 projections considerably ner than the main tapered stem. The admirable sweeping properties of broom corn are attributable to the liexing Vaction imparted by the decreasing diameters in the direction of the sweeping ends of the individual bers and by the multiplicity of fine sweeping ends present at the working end of a completed broom.

Less work has been conducted in the direction of developing an adequate synthetic replacement for corn broom because that material is still readily available at reasonably low cost. Standard, uniform solid laments of circular shape have been used to a considerable extent in so-called linoleum brooms that are used as a substitute for corn brooms. In some instances, filaments have been used which have been manufactured using filaments whose composition consists of two incompatiblethermoplastics. These laments, when oriented, have interfaces of incompatibility running the length of the filaments which split readily when the laments are subjected to flagging action. Such larnents have not been made with decreasing stiffness in the direction of the Working end and show a tendency to split uncontrollably and thereby cause premature brush failure.

. Thus, an ideal synthetic brush ber should be one which has decreasing stiffness, not necessarily decreasing diameter, in the direction of the working end; be such that it may be readily flagged; be of such shape that the mechanical forces to which it is subjected during sweeping service causev flagging to continue lasthe ber wears; have maximum tip surface exposed to the direction of the sweeping Ior paint application; and, when capillarity is required, have grooves the length of the larnent to assistv in liquid retention.

Objects and advantages of the invention will be set forth in part hereinafter and in part will be obvious herehom, or may be learned by practice with the invention, the same being realized and attained by means of the steps, methods, `combinations and improvements pointed out 4in the appended claims.

The invention consists in the novel steps, methods, combinations' and improvements herein shown and described.

An object of this invention is to provide a novel ber wglich is referred to herein as an increasingly spatulated er. meant a ber having (along its increasinglyspatulated portion) a varying cross-sectional shape along the length of the ber and having a progressively decreasing thickness, a corresponding increasing width and a corresponding decrease in stiifness in the spatulating direction. By spatulating direction is meant a direction normal to both the longitudinal axis of the ber and the line of greatest width.

Another object of this invention is to provide a ber which has at least two increasingly spatulated portions along its length in different spatulating directions, one spatulating direction preferably being in a direction from a second spatulating direction.

In the drawings:

FIG. 1 is a longitudinal sectional view of a hollow cy lindrical lament which may be flattened in accordance with this invention. FIG. 1al is a cross-sectional view alongithelirie laf-,1a of FIG. 1.

FIG. 2 is a longitudinal sectional View of .a hollow striated filament which may be flattened in accordance with this invention. FIG. 22L is a cross-sectional View along the line 2a-'22L of FIG. 2.

FIG. 3 is a longitudinal sectional view of a hollow square lilament whichv may be flattened in accordance with By the term increasingly spatulated ber is' 3 this invention. FIG. 3a is a cross-sectional view along the line Saa of FIG. 3.

FIG. 4 is a perspective view of a hollow filament having longitudinal grooves which may be flattened in accordance with this invention. FIG. 4a is an end view of the filament of FIG. 4.

FIG. 5 is a perspective view of an X-shaped filament which may be flattened in accordance with this invention. FIG. 5a is an end view of the filament of FIG. 5.

FIG. 6 is a plan view of the hollow filament of FIG. 1 after it has been fiattened. FIG. 6a is a longitudinal sectional view along the lines 6ft-6a of FIG. 6. FIGS. 6b, 6c and 6d are cross-sectional views along the lines B-B, C-C and D-D respectively of FIG. 6a.

FIG. 7 is a front elevational view of the X-shaped filament of FIG. 5 after'it has been flattened. FIGS. 7a, 7b and 7G, respectively, are cross-sectional views along the lines A-A, B-B and C-C, respectively of FIG. 7.

FIGS. -8 and 9 are graphs illustrating the decreases in stiffness and thickness along the lengthl of the spatulated hollow fiber of FIG. 6 as the cross-section of the filament goes from circular at 6b to the flattened portion at 6d.

FIGS. 10 and 11 are graphs illustrating the decreases in stiffness and thickness along the length of the X-shaped spatulated fiber of FIG. 7 as the cross-section goes from the X-shape at 7a to the spatulate at 7c.

FIGS. 12 and 13 illustrate the diameter and stiffness correlations of corn broom fiber.

FIG. 14 is a diagrammatic view of a spatulated fiber of this invention which illustrates how the working fiattened end covers a much larger sweeping area than would the small tip of a conventional filament of the type shown in FIG. 15 which has a reduced diameter in the direction of the working end.

FIG.- 16 is a front elevation view of a mold useful in fiattening the filaments of an already formed brush. FIG. 17 is a sectional view` along the lines 17-17 of FIG. 16.V n

FIG. 18 is a perspective view illustrating how the mold of FIGS. 16 and 17 may be used to flatten a predetermined quantity of individual fibers capable of deformation which are not connected to a brush block. FIG. 19 is a diagrammatic view of a brush-like product flattened in the manner illustrated in FIG. 18 with the protruding ends heat welded or cemented together.

FIG. 20 is a front elevation view of a broom construction employing filaments flattened in accordance with this invention.

FIG. 21 is a perspective view of a mold base construction used in deforming a family of filaments ata plurality FIG. 23 is a sectional view taken along the line 23-23' of FIG. 21 with the complementary side plates in position.

FIG. 24 is a sectional view taken along the line 24-24 of FIG. 21.

FIG. 25 is a fragmentary front view of protruding spatulated fibers after removal of the bottom plates of the mold construction shown in FIG. 24.

FIG. 26 is a front elevational view of a fiber produced in accordance with this invention having double deformation. FIGS. 26a to 26C, respectively, are cross-sectional views taken along the lines A-A, B--B and C-C, respectively, of FIG. 26 of perfectly spatulated fibers.

FIG. 27 illustrates an analysis of actual configurations for the sections locations A-A, B-B and C-C of FIG. 26 based upon a brush doubly fiattened in the mold of FIGS. 21 to 24.

FIGS. 28 and 28a illustrate diagrammatically the formation of a `brush construction wherein the brush block and integral handle are formed from melted non-working ends of brush Vfibers fused to a solid mass welded to the family of fibers of the brush construction. FIG. 28b

shows the brush construction resulting from the process illustrated in FIGS. 28 and 28a.

FIG. 29 illustrates diagrammatically the formation of a brush construction wherein a brush block having means for attachment of a handle is formed from melted nonworking ends of brush fiber fused to a solid mass welded to thefamily of Vfibers of the brush construction.

FIG. 30is a front elevational view of a handle adapted to be screwed into the threaded portion of the brush construction of FIG. 29 to form a brush and handle combination shown as a front elevational view in FIG. 31.

FIG. 32 is a front elevational view of a brush construction formed in accordance with the present invention wherein the brush block is provided with a tapered hole adapted to receive a complementary projection on the handle shown as a front elevational view in FIG. 33.

FIG. 34 is a diagrammatic view of a mold arrangement used `in the formation of a brush having a tent-like construction.

FIG. 35 is a diagrammatic view of the brush construction formed by using the mold arrangement of FIG. 34. t

FIG. 36 is a diagrammatic View of a mold arrangement used in the formation of a brush construction having parallel rows of fibers. The brush construction is shown diagrammatically in FIG. 37.

FIG. 38 is a diagrammatic view of a brush formed in accordance with this invention wherein there is provided a brush block with attaching device of extremely thin plastic.

FIG. 39 illustrates diagrammatically they spatulation of a plurality of a band of solid filaments.

It has been found that syntheticfibers having ideal brush fiber characteristics may be produced by providing a family of synthetic fibers which are increasingly fiattened in the direction of one common end, the fibers at the other common end being supported in such a man-r vthat they are compressible and capable of being permanently deformed when pressure is Vapplied thereto at a temperature below their melting point. In general, synt thetic fibers fiattened in accordance with this invention are thermoplastic filaments of the type normally used as brush fibers such, Vfor example, as vinyl chloride polymer` tion needed for proper spatulation be performed at thek heat-setting temperature of the material being used and that sufficient cooling be subsequently employed while the deformed or spatulated fiber remains under `deforming compression to lock the stresses of spatulation in position.

As indicated above fibers flattened in accordance with i this invention must be compressible and capable of being permanently deformed at a temperature below their melting point. FIGS. 1 to 5 of the drawings illustrate different shaped thermoplastic filaments capable of deformation. FIG. 1 shows a hollow filament which may be fiattened in accordance .with this invention. When the filament of FIG. 1 is subjected to compressive force such that deformation or flattening of the fiber increases from one end of the filament to theL other, it changes to the. configuration illustrated in FIGS. 6--6Cl of the drawings.

Reference is made to FIGS. 2 to 5 which illustrate other embodiments of filaments which may be flattened in accordance with this invention. FIG. 2 shows an alternate construction where two hollow striations run the length of the fibers. FIG. 3 shows a square hollow fiber and it is apparent that oval or other starting shapes may Y material.

be used. FIG. 4 shows a cylindrical lament having longitudinal grooves which assist capillarity. FIG. 5 shows an X-shaped filament which obviously already has grooves which are most effective from a capillarity standpoint. jected to compressive force such that deformation of the ber increases from one end of the lament to the other, it changes to the conguration shown in FIG. 7. Obviously instead of X-shaped filaments, laments of other deformable shapes may be used such as those having X, H, etc. structural cross-sections.

In general, the diameter of the starting cylindrical `lament of the type shown in FIG. 1 is in the range of 0.005 to 0.200 and the Wall thickness is generally in the range of 0.001" to 0.050" depending upon the rigidity desired in the formed ber. The laments shown in FIGS. 2 to 5 would have the same general maximum and dimensions as indicated for the shapeA of the filament of FIG. 1.

In the case of tubular vinyl chloride-acetate filaments as shown in FIG. 1 and for the other shapes described, the filaments are heated to 212 F. and cooled to 140 F. under the .deforming force at which temperature the stresses of spatulation are locked in place. Further cooling gives additional insurance that the stresses are properly locked.

In the case of tubular filament `made using a polymer based uponthe condensation of hexamethylene diamine and sebacic acid, deformation may be performed at 300 F. Vand since, in nylon of this type, the deformed shape is permanent at any temperature below 300 F. orV the deforming temperature, only a-small amount of cooling is required to set the deformation.

As the cross-section of the formedspatu-lated filament of FIG. 6 goes from circular at 6b to the fiattened portion at 6b, stiffness and thickness of the filament as measured between attened. surfaces decreases .as shown in the graphs of FIGS. 8 and 9. Deformation of the X-shaped ber of FIG. 7 gives stiffness and thickness correlations in graphs of FIGS. 10 and 11. It is apparent that decreasing stiffness in -the direction of the working end of spatulated hollow circular fibers as shown in FIG.- 6 and spatulated X-shaped bers as shown in FIG. 7 can, through proper design, be made to simulate in the direction of sweeping the stiffness characteristics of corn broom fiber the diameter and stiffness correlations of which are shown in the graphs of FIGS. 12 and 13.

The attened Working ends of bers as shown in FIG. 6 and FIG. 7 flag much more readily than does a solid circular shape and the forces applied to such spatulated product during usage are such that flagging continues vas the brush wears.

It isapparent from FIG. 14 that the flattened end 10 of a fiber, formed in accordance with this invention, covers a much larger sweeping area in the direction of sweeping 11, than would the small tip 12, of a filament having reducing diameter in the direction of the working When the X-shaped filament of FIG. 5 is sub-- product in which the attened ends are aligned with their major dimension at right angles to the direction of sweepend as shown in FIG. 15. The 'spatulated fiber is therea single ber 10, is shown aligned at right angles to the direction of sweeping 11, in FIG. 14.

This can be readily done with a brush that has been manufactured by conventional methods previously de` scribed using fibers capable of deformation as the filling Insertion of a family of compressible fibers protruding from a brush block into a mold as shown in ing or painting.

As shown in FIGS. 16 to 18, the upper pa-rt 21, of the mold 20, is guided into the lower part 22, of the mold by means of guide pins 23, after the compressible family of bers of an already formed brush (not shown) has been placed in the cavity 24. As showed in FIG. 17, the mold is provided with an end plate 20. As the mold closes to apply a pressure P before, during, or after heating the fiber to its suitable forming temperature, the angled surfaces 25, on the upper part 21, of the mold, and the lower part 22, of the mold, compress the fibers and result in overall deformation of the family of fibers inthe direction of the working end of the brush.

The above explanation relates to deforming the fila- 'ments of an already formed brush. A pre-determined quantity of individual fibers capable of deformation which are not connected to a brush block can be processed similarly as in FIG. 18. In this cas-e unconnected compressible ber ends 26 extend from the closed mold at 26'. These extended ends may be heat-welded or cemented as at 27 in FIG. 19 to give a brush-like product in which the flattened tips 28, are aligned with their major dimensions at right angles to the direction of sweeping 29. As indicated heretofore, in the case of a polymer made from hexamethylene diamine and sebacic acid, the heat-sealing temperature used on the protruding ends would be in the order of 450 to 600 F. In the case of vinyl chloride-acetate, the welding temperature would be in the order of 275 to 400 F.

In a number of instances, i-t is desirable to make brooms with shape as shown in FIG. 20. This can be accomplished by deforming the non-working ends in the opposite direction from the deformation imparted to the Working ends.

This effect may be obtained by placing a pre-determined quantityof individualy fibers capable of deformation in cavity 30 shown in FIG. 21 and FIG. 24 with the angular members 31, 31' and their lower attachments`32, 32 withdrawn in the direction of the spacer members 33 and 34. The lower attachments 32, 32 are each removably secured to angled members 31, 31 by means of fastening bolts 32a. Locating studs 35, 35 are in threadedengagement with spacer members 33 and 34 and at their free ends abut angular members 31, 31'. Removably secured to angular members 3-1, 31' are supporting pins 36, 36 which are slidably received in and extend through spacer members 33 and 34. Rotation of stud members 35, 35. in appropriate directions cause forces to be applied to angular members 31, 31 in direc-tions indicated by F and F. This causes movement of angular members 31 and 31' (and their attachments 32, 32') towards each other. The aforedescribed movement of the opposing angular members 31, .31' and attachments 32, 32 toward each other enables the angular members 31, 31 and attachments 32, 32' to press against the contained ber to effect deformation thereof. This movement may be effected before, during, .or after heating the contained ber -to its heat setting temperature. As shown in FIG. 24, the angular members 31, 31 and attachments 32, 32' deform the fiber in cavity 30 below line C-C. The height of C-C depends on the quantity of liber charged into the cavity and the angle of members 31, 31 and 32, 32. Fiber above C-C which is not compressed by members 31, 31' tends to 'are out as shown in FIG. 24.

Side-plate member 37 is placed on pins 38 on member 39 in FIG. 21 by means of holes 40 in plate 37. Integral` with plate member 37 is a Wedge member 41 having an inclined surface 41a. A member 37 similar to 37 is placedA in the cavity above C-C is effected on the working ends of the fibers by surfaces 41a in a direction opposite to the deformation applied by members 31, 31 and 32, 32 below line C-C.

Removal of plate 37 from part 39 and a corresponding plate 37 from part 39' and the two parts 32, 32 from parts 31, 31 in FIG. 24 by removal of fastener bolts 32a leaves fiber extending below surface 43 of FIG. 21 and as shown in FIG. 25. This fiber extension may be heatwelded or cemented as shown at 27 in FIG. 19. The same choice of temprature cycles exists for this double deformation as for the single deformation described in connection with the mold shown in FIG. 16.

Perfectly deformed fibers of the double spatulation type would have varying cross-sections as shown in FIG. 26@- 26c. However, when a family of fibers is flattened, inter ference from adjacent fibers prevents perfect deformation. Analysis of actual configurations for the section locations shown in FIG. 26 are depicted in FIG. 27. The analysis l was based upon a brush double deformed in the mold shown in FIGS. 21 to 24.

It should be realized that the analysis shown in FIG. 27 is merely for the purpose of illustrating the different sectional configurations that were obtained for a given set of conditions. Deformation is a function of deforming pressure so that various degrees of deformation other than those shown are obtainable and controllable.

Deformation of a brush made by conventional methods, and single or double deformation of a family of individual fibers followed by heat-sealing or cementing of the nonworking ends of same to maintain the desired alignment of these fibers has been described.

Heat-sealing or welding is preferable to cementing. It follows then that welding or heat-sealing is an integral part of the manufacture of certain spatulated brushes. This recognition has made apparent a new concept for the manufacture of brushes which goes hand in hand with the croncept of spatulated brushes.

This concept consists of melting the non-working ends of fibers capable of `deformation by contact in a heated cavity whose shape corresponds to the shape of a brush block while at the same time molding means in the block for subsequently attaching Ia handle to the molded block. If the necessary brush handle was sufficiently small, it could be made an integral par-t of the molded block.A

The advantages of this method of vmaking brushes is apparent when one considers the conventional methods presently `used for brush manufacture.

In the case of corn brooms, the fibers are arranged around one end of the handle and affixed by spiral wire winding the arranged fibers to the shaft 'or handle. Construction of each broom is a laborious matter.

Paint brushes are made by arranging the fibers in suitable shape, irnpregnating the non-painting ends with epoxy, rubber, or o-ther base cement-s in one end of a metal ferrule, curing the cement, and afi'iX-ing a handle to the opposite end of the ferrule from that in which the fibers are inserted.

Staple set brushes are made by pre-drilling holes in a plastic or wooden block, inserting fiber tufts bent in U shape into these holes and retaining the tufts with anchors or staples. In some instances the tuftsfare set with pitch rather than with staples. In other instances the U-shaped tufts may be retained by a wire which retains the tufts and runs from hole to hole.

Other brushes have been made by injection molding the block and coarse fibers simultaneously; injecting hot thermoplastic in the form of a stream around a group of fibers; retaining fibers in U shape in a U-shaped metal strip with a wire, and by twisting two wires together with fiber between them.

Individual tufts have been heat-sealed at one end and used to fill single holes in staple-set brushes which the machine missed. There is no knownfinstance where the melted non-working ends of brush fibers have been used g to form la finished commercial brush block having meanstherein for subsequently attaching a handle to the molded block. Nor is it known to form a brush block in the manner described .above wherein the handle is made an integral part of the molded block.

Certain thermoplastic brush fibers such as those made from-hexamethylene diamine sebacic acid polymers, polycaprolactam and others are of such fiuid nature when melted that gravity flow is sufficiently great to fill a cavity having the shape of a brush block if the cavity is heated above the melting point of the thermoplastic fiber being melted. Thus when a family of spatulated or nonspatulated thermoplastic fibers of the type described is permitted to melt and settle into a heated cavity having a shape corresponding to .a desired brush block, and providing either means forrattaching a handle to the molded brush, or, providing a handle as an integral part 4of the brush, melting of the fibers occurs, thel cavity fills with melted polymer,` and the resultant cooled product consists of .a block made from melted fibers to which the unmelted fibers are welded in upright position.`

Such an operation is demonstrated in FIGS. 28 and 28a. These figures illustrate the production of a brush construction wherein there is formed an integral handle on the brush block. Spatulated fibers are retained with their working tips in essentially parallel arrangement in re-` tainer 50. -As retainer 50 is lowered into cavity 51 in mold 52 which is heated by elements 53 to a temperature above the melting point of the fibers in 50, the fibers melt andform a handle54 and block 55 to which the fibers in container 50 arewelded. FIG. 28b illustrates the appearance of the brush upon removal from the cavl too unsightly but degradation of the polymer would rej main.

4It has been established that performance of the function shown in FIGS. 28` and 28am aninert atmosphere l such as nitrogen,V carbon dioxide, or Vacuum results in a product whose properties are not degraded. When meltl ing is conducted in a vacuum, there is the added advantage that the presence of voids in the melted block is minimized.

It is further believed that the manufacture of a brush in an inert atmosphere permits considerations that were not heretofore practical and applies to existing synthetic fibers :as well as the new spatulate form.

For instance, in FIG. 29 the mold cavity 60 is provided with a removable screw V61, protruding ,into it. When melted fiber is molded around the screw and the screw is removed after cooling, .a female `thread is left in the molded block to which a handle with a corresponding male threadcan be affixed. Where the fiber being melted is sufficiently compressed as would be the case with fiber deformed in the mold shown in FIG. 24, the heated screw 61 could be screwed through mold 60 and cut its own -thread 4into the compressed fiber to a point 62 higher than the melted polymer level 63 .and would leave i into which the projection 67 on the handle 68 of FIG. 33

could be force fitted to give a finished brush. The handle could if desired be made to fit sideways or in any other direction.

Similarly, dissimilar bers chemically could be flattened together but it would be preferable that these dissimilar bers be compatible.

In the manufacture of certain brushes, it is desirable to impart a tent effect to the arranged brush bers. Such a product may be formed following the techniques previously described in a mold consisting of three parts as shown in FIG. 34. The bers 70 are retained at the desired angle between parts 7.1 and 73 and part-s 72 and 73. The ber 70 may be either spatulated or non-spatulated. When the protruding ends of 70 are heat melted in a cavity as previously described a brush structure simulating .a tent effect is obtained as shown by the brush construction 74 of PIG. 35.

In FIG. 36 parallel rows of spatulated or non-spatulated ber are retained by parallel segments 80 of a retaining mold. Fusion of the ber extensions 81 in a heated cavity as described results in a brush structure 82 as shown in FIG. 37.

It is is apparent that structures other than those shown could be devised.

A further advantage of the melt process for making a brush lies in the fact that the block with attaching device 90 as shown in FIG. 38 can be made of extremely thin plastic 91 with minimum thickness webs 92 incorporated in the case structure to provide necessary block stiffness. Use of parallel rows of ber 93 in such a brush as made in the mold depicted in FIG. 36 results in successive continuous rows of ber which are a more effective sweeping medium than staggered rows of holes filled with ber.

In certain instances, it may be desirable to introduce melted polymer into the block cavity to supplement that part provided by melted lament. The advantage would be that such supplementary melted polymer would cost less than an equivalent weight of melted brush ber. Such supplementary melted polymer could be added to the cavity as granules which would melt in contact with the heated cavity or as a stream of molten polymer. In either case, part of the block would necessarily consist of melted ber to secure necessary welding. The supplementary polymer described may not be the same material as the melted brush ber but it would preferably be one that is compatible with the polymer of which the melted ber consists.

In the apparatus described hereinbefore for spatulating filaments, conventional solid laments, e.g. circular solid laments may be attened individually using the thermoplastics noted but in a family of solid circular bers, with the apparatus used for deforming the various embodiments described hereinbefore, deformation is ineective because the circular solid laments occupy so much cross-section that they cannot ow into spatulated form. Special apparatus and techniques may be provided, however, for attening a family of solid laments.

Reference is now made to FIG. 39 which illustrates diagrammatically apparatus and techniques for flattening a family of solid circular laments. More particularly, a band of bers 100 is spread on a roll 101 which is in association with an eccentrically mounted smaller roll 102 whose ececntric axis is designated 103. The band of laments 100, pulled between rolls 101 and 102 by force A, are flattened over part of their length between surfaces 104 and 105 of rolls 101 and 102, respectively, which are rotated such that these surfaces move in the direction of the band of filaments 100. As the radial distance between of flattening increases.

It is obvious that solid laments of any cross-section may be deformed in accordance with the abovedescribed technique. It is also clear that Various modications may be employed to eiect the desired deformation. For example, in place of the eccentrically mounted roll 102, one may use a roll of a trefoil shape.

In summary, it has been shown that spatulated synthetic brush bers more closely approach the desirable properties of certain natural brush bers than any synthetic brush ber devised to date; that these s patulate fibers may be attened in conventionally made brushes; that spatulated bers may be melted at their non-working ends to x the attened ends in proper relationship; that the melted non-working ends may form a multiplicity of shapes which would act as the nished brush block; and that by conducting the melting ofthe non-working ends in a cavity in an inert atmosphere degradation of the color and physical properties of the melted non-working ends is avoided.

It has been shown that the physical properties of heatsetting temperatures, melting characteristics, and structural strength of the melted brush bers have become for the rst time considerations .that should be weighed in the manufacture of a brush.

The invention in its broader aspects is not limited to the specic steps, methods, compositions, combinations and improvements described but departures may be made therefrom within the scope of the accompanying claims without departing from the principles of the invention and without sacricing its chief advantages.

What is claimed is:

1. An increasingly spatulated ber for use in brushes comprising a synthetic ber which is of a compressive nature and which has an increasingly spatulated portion along .at least part of its length, said increasingly spatulated portion having a varying cross-sectional shape along the length of the ber and having a progressively decreasing thickness, a corresponding increasing width and a corresponding decrease in stiffness in the spatulating d- 2,264,415 12./ 1941 Taylor et al. 264-167 2,356,886 8/1944 Reis 264-167 X 2,508,799 5/ 1950 Reis 161-177 X 2,558,334 6/1951 Baumgartner 15--159 ALEXANDER WYMAN, Primary Examiner.

EARL M. BERGERT, Examiner.

G. MORRIS, Assistant Examiner, 

1. AN INCREASINGLY SPATULATED FIBER FOR USE IN BRUSHES COMPRISING A SYNTHETIC FIBER WHICH IS OF A COMPRESSIVE NATURE AND WHICH HAS AN INCREASINGLY SPATULATED PORTION ALONG AT LEAST PART OF ITS LENGTH, SAID INCREASINGLY SPATULATED PORTION HAVING A VARYING CROSS-SECTIONAL SHAPE ALONG THE LENGTH OF THE FIBER AND HAVING A PROGRESSIVELY DECREASING THICKNESS, A CORRESPONDING INCREASING WIDTH AND A CORRESPONDING DECREASE IN STIFNESS IN THE SPATULATING DIRECTION. 